Which Welding Process is Best

Which welding process is best? That depends on the application. The following is a short
description of each:
Arc (Stick) Welding or SMAW (Shielded Metal Arc
Welding):
Arc welding is one of the oldest welding processes around. It can be the cheapest to start with as
there is not a lot of equipment needed. It is also very versatile as there a lot of specialized
electrodes available. ome of the main features and limitations are:
• Ine!pensive
• "as specialized electrodes for hardening# high$strength# stainless# mi!ed# cast iron and
other metal alloys
• %ses a flu! coating to shield weld.
• Weld will need to have flu! cleaned off
• &ery difficult on thin metal
• Ta'es considerable training and practice to master.
• (ortable as no need to carry gas or wire feeder.
• Wor's on A) or *)
Arc welding is nice for its simplicity in the equipment. It ta'es practice to do consistent and
proper welds.
There are dozens of types of rods +electrodes, available. ome of the most common are:
• -.// $ *eep penetration# cellulose
• -./0 $ 1eneral purpose# easy to use.
• 2./3 $ 4ow (enatration# great for thin metal
• 2./5 $ 4ow$hydrogen# higher strength. 6ods need to be 'ept dry# usually in an oven.
They are also more productive as far as amount of weld per minute.
• 7ic'el8ilicon $ *esigned for )ast Iron. Two main types depending on 7ic'el content.
"igh nic'el content is stronger but very hard and cant be machined. 4ower nic'el content
for machinability.
• tainless $0.5# 0.9 and 0/- grades available.
:ost *I; welders will use -./0 rods as they are widely available and relatively easy to use.
7ote# the quality of the rods ma'e a big difference on their ease of use.
<lectrodes can be purcased in differnt sizes from /8/-= to /83=. >or *I; use /85= or less will be
used. I find ?8-3= or 080@= rods are the most useful.
7ote: thin metal is difficult with arc welding. I found some /8/-= +/.-mm, 2./3 rods that wor'
well on ...3. steel.
MIG Welding
:I1 welding +:etal# Inert 1as, welding is also call 1:AW +1as# :etal Arc Welding., It uses a
thin wire as an electrode and filler fed by a wire feeder to the gun. The power source is constant
voltage +)&, *).
There are two main process 1as +:I1, and gasless +flu! core., Aelow is a comparison of the
two:
Gasless MIG (FCAW - Flux Core Arc Welding):
• *oes not need shielding gas# saves cost of bottles# regulator.
• Wire is more e!pensive.
• It is more portable# no gas to transport.
• %ses flu! core to shield weld. )auses slag and spatter that must be cleaned up.
• (roduces smo'e that ma'es it hard to see weld.
• "as deeper penetration than gas :I1.
• <asier on positional welds +overhead and vertical.,
• *irect$)urrent# <lectrode 7egative (olarity +*)<7,
• mallest wire available is ...0.= +..5mm,B not easy to use on thin metal.
Gas MIG (GMAW):
• &ery clean welds with no slag or spatter.
• %ses Argon8)C@ or straight )C@ as a shielding gas.
• Wire is less e!pensive.
• :ore comple! than >lu! )ore
• 4ess portable
• *irect$)urrent# <lectrode (ositive polarity +*)<(,
• Wire size down to ...@0: +..-mm,# great for thin metal.
The wire is fed via from a roll wire feeder to the gun. :I1 is the easiest process to learn# but
requires gas and a wire feeder so it is not as portable. :I1 is great for thin metal especially auto
body wor'.
TIG Welding, GTAW (Gas Tungsten Arc Welding):
TI1 welding is also very versitile and produces the highest quality welds. It also ta'es
considerable practice and is least productive.
TI1 uses an torch with a tungsten electrode. Argon is used as a shielding gas to protect weld and
tungsten. An arc is struc' between the tungsten and the wor' and a short gap is maintained. As
the weld progresses# filler wire is dipped in the weld pool. (ower source is constant$current *)
or A) depending on metal used.
)ontrolling the torch# feeding wire# moving at the right speed and also using the correct current
ma'es it physically more complicated. %sing a footpedal# you have / foot and both hands busy.
It is easier for bench wor' +I use a barstool .,
TI1 can do Dust about any metal with A) and a *) power source. *) is used on ferrous metals
+steels., A) is used on aluinum. This *I; welder only does *).
So, Which o I !se"
As usual# that depends B,
>or building a *I; welder# arc welding is cheapest and simplest. It is a versitile starting point.
1reat for farm repairs as it is the most portable. *ifficult on thin metal.
If you plan on doing bodywor'# then gas :I1 is best. That will require adding a wire feeder#
gun# gas bottle and regulator to the basic arc setup. I prefer :I1 for its clean welds. "owever# if
I need to lug the welder out somewhere for a quic' fi!# I use stic'.
If you are building something li'e a off$road buggy frame# then TI1 is preferred as you have the
most control over the welds.
I use arc 5.E of the time. TI1 for aluminum and :I1 for thin metal.